BRAKE ACTUATOR INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. for Type A Brake Actuator Assembly:


      1. A01LUWUN01

        Install the brake actuator assembly to the brake actuator bracket assembly with the bolt and 2 new nuts.

        Torque:
        Bolt
        5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
        Nut
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

        Note


        • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake lines because the brake actuator assembly is filled with brake fluid.

        • Do not hold the brake actuator assembly by the connector.

        • Tighten the bolt and 2 nuts in the order shown in the illustration.

    2. for Type B Brake Actuator Assembly:


      1. A01M2Y4N01

        Install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.

        Torque:
        5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

        Note


        • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake lines because the brake actuator assembly is filled with brake fluid.

        • Do not hold the brake actuator assembly by the connector.

        • Tighten the 3 bolts in the order shown in the illustration.

  2. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. for Type A Brake Actuator Assembly:


      1. A01M2FDN01

        Install the brake actuator with bracket to the vehicle body with 3 new nuts.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

        Note


        • Do not damage the brake lines, fuel lines or wire harness.

        • Tighten the 3 nuts in the order shown in the illustration.

      2. Engage each clamp to install the No. 2 fuel tube clamp and front No. 4 brake tube to the brake actuator bracket assembly.

        Note

        Do not damage the brake lines or fuel lines.

      3. A01M098C01
        *a

        for LHD:

        From 1st Chamber of Master Cylinder Sub-assembly

        for RHD:

        From 2nd Chamber of Master Cylinder Sub-assembly
        *b

        for LHD:

        From 2nd Chamber of Master Cylinder Sub-assembly

        for RHD:

        From 1st Chamber of Master Cylinder Sub-assembly
        *c To Front Wheel Cylinder Assembly RH
        *d To Rear Wheel Cylinder Assembly LH
        *e To Rear Wheel Cylinder Assembly RH
        *f To Front Wheel Cylinder Assembly LH

        Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

      4. A01LV1NC01
        *a Torque Wrench Fulcrum Length

        Using a union nut wrench, fully tighten each brake line.

        Torque:
        Specified tightening torque (A) (w/o VSC)
        15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }
        Specified tightening torque (A) (w/ VSC)
        19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
        Specified tightening torque (B)
        15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Click here

        • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

          w/ VSC (A): 17.36 N*m (177 kgf*cm, 13 ft.*lbf)

        • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

          w/o VSC (A), (B): 13.38 N*m (136 kgf*cm, 10 ft.*lbf)

      5. A01M2R4N02

        Engage the clamp to install the wire harness to the brake actuator bracket assembly.

      6. Connect the connector to the brake actuator assembly and disengage the claw (b).

      7. Pull the lever down and engage the claw (a) to engage the connector lock.

        Note


        • Make sure that the connector is locked securely.

        • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

    2. for Type B Brake Actuator Assembly:


      1. A01M39ZN01

        Install the brake actuator with bracket to the vehicle body with the 3 nuts.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

        Note


        • Do not damage the brake lines, fuel lines or wire harness.

        • Tighten the 3 nuts in the order shown in the illustration.

      2. Engage each clamp to install the No. 2 fuel tube clamp and front No. 4 brake tube to the brake actuator bracket assembly.

        Note

        Do not damage the brake lines or fuel lines.

      3. A01M145C01
        *a From 1st Chamber of Master Cylinder Sub-assembly
        *b From 2nd Chamber of Master Cylinder Sub-assembly
        *c To Front Wheel Cylinder Assembly LH
        *d To Rear Wheel Cylinder Assembly RH
        *e To Rear Wheel Cylinder Assembly LH
        *f To Front Wheel Cylinder Assembly RH

        Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

      4. A01M1PTC01
        *a Torque Wrench Fulcrum Length

        Using a union nut wrench, fully tighten each brake line.

        Torque:
        Specified tightening torque
        15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Click here

        • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

          13.38 N*m (136 kgf*cm, 10 ft.*lbf)

      5. A01LVM1C01
        A01M03W Connect
        A01LZQW Lock

        Connect the connector to the brake actuator assembly and lock the lock lever.

        Note


        • Make sure that the connector is locked securely.

        • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

    3. Connect the connector to the ECM.

      for 1NR-FE: Click here

      for 1ZR-FE: Click here

      for 1ZR-FAE: Click here

      for 2ZR-FE: Click here

      for 8NR-FTS: Click here

  3. INSTALL BRAKE ACTUATOR COVER (for 1WW, 1ND-TV with VSC)


    1. Raise the claw of a new brake actuator cover, insert the pin into the hole and engage the claw to install it to the brake actuator assembly.

      A01LYWNC01
      *a Claw *b Pin

  4. INSTALL AIR CLEANER BRACKET (for 1WW, 1ND-TV)


    1. Install the air cleaner bracket with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  5. INSTALL FUEL FILTER SUPPORT (for 1WW, 1ND-TV)


    1. Install the fuel filter support with the 3 bolts.

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

    2. Engage the wire harness clamp to the fuel filter support.

  6. INSTALL GLOW PLUG RELAY ASSEMBLY (for 1WW, 1ND-TV)


    1. Install the glow plug relay assembly to the fuel filter support with the bolt.

      Torque:
      for 1ND-TV
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      for 1WW
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

    2. Connect the wire harness clamp to the fuel filter support.

  7. CONNECT WIRE HARNESS (for 1ND-TV)


    1. Connect the ECM connector to the ECM.

      w/o Glow Plug Controller: Click here

      w/ Glow Plug Controller: Click here

    2. Connect the 3 wire harness clamps to the fuel filter support.

  8. CONNECT WIRE HARNESS (for 1WW)


    1. Connect the ECM connector to the ECM.

      Click here

    2. Connect the 2 wire harness clamps to the fuel filter support.

    3. Connect the connector.

  9. INSTALL FUEL FILTER ASSEMBLY (for 1WW, 1ND-TV)

    for 1WW: Click here

    for 1ND-TV: Click here

  10. INSTALL NO. 1 FUEL FILTER PROTECTOR (for 1WW)

    Click here

  11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1NR-FE)

    Click here

  12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1NR-FE)

    Click here

  13. INSTALL NO. 1 ENGINE COVER (for 1NR-FE)

    Click here

  14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FE)

    Click here

  15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FE)

    Click here

  16. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FE)

    Click here

  17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  19. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)

    Click here

  20. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FE)

    Click here

  21. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE)

    Click here

  22. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)

    Click here

  23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ND-TV)

    w/o Glow Plug Controller: Click here

    w/ Glow Plug Controller: Click here

  24. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ND-TV)

    w/o Glow Plug Controller: Click here

    w/ Glow Plug Controller: Click here

  25. INSTALL NO. 1 ENGINE COVER (for 1ND-TV with No. 1 Engine Cover)

    w/o Glow Plug Controller: Click here

    w/ Glow Plug Controller: Click here

  26. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 8NR-FTS)

    Click here

  27. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 8NR-FTS)

    Click here

  28. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1WW)

    Click here

  29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY (for 1WW)

    Click here

  30. INSTALL NO. 1 ENGINE COVER (for 1WW)

    Click here

  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  32. BLEED AIR FROM FUEL SYSTEM (for 1ND-TV)

    Click here

  33. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK (for 1WW)

    Click here

  34. INSPECT FOR FUEL LEAK (for 1ND-TV)

    w/o Glow Plug Controller: Click here

    w/ Glow Plug Controller: Click here

  35. BLEED BRAKE SYSTEM

    Click here

  36. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  37. PERFORM SYSTEM VARIANT LEARNING (w/ VSC)

    Click here

  38. CHECK FOR AND CLEAR DTCS

    w/o VSC (for Type A): Click here

    w/o VSC (for Type B): Click here

    w/ VSC: Click here